Flush corner metal frame construction



April 28, 1953. H. J. BIANCO FLUSH CORNER METAL yl-"RANTT CONSTRUCTION 2 SHEETS-SHEET 1' Filed June 27, 195o 17e/MJ 23M f mu/ @WMU 2- sgEETs-sx-IET 2 "H. J. BIANCO FLUSH CORNER METAL FRAME coNs'rRucTIoN I IIII ,Illlllllllll'lllllllI1ll|l|l April 2s, 1953 Filed June 27, 1950 www ,as I

IAIIIIIIIIIIIIIII Patented Apr. 28, 1953 FLUSH CORNER METAL FRAME CONSTRUCTTON Henry J. Bianco, Baltimore, Md., assignor to The Burch Company, Baltimore, Md., a corporation of Maryland Application June 27, 1950, Serial No. 170,655

(Cl. I89-76) 4 Claims.

The present invention relates to a metallic frame for window sash, doors, etc., andv more particularly to a metal frame construction in which the corners are flush and devoid of recesses, cavities, etc.

The principles of the present invention are applicable to metal frame constructions in general, but for purposes of illustration and not by Way of limitation, the same Will be described in detail in connection with a Window sash frame. With the foregoing in mind:

The principal object of the invention is to provide a metal frame structure Which is quite rigid, and which can be manufactured to close tolerances by' mass production methods.

Another object of the invention is to provide a flush corner frame structure that can be made from either rolled or extruded metal shapes, preferably aluminum alloy, and constructed in a minimum of time and with a minimum of waste of material.

Another object of the invention is to provide a frame` constructed from relatively inexpensive channel-shaped sections and provided with a Hush corner joint that presents a neat and pleasing appearance, devoid of recesses, cavities or depressions.

A further object of the invention is to provide an aluminum alloy sash frameadapted to be mounted in runways or guide rails formed of a similar metal, but which has incorporated therein bearing means for preventing galling or seuffng of the metal and which will reduce friction between the sliding parts. y

vA still further object of the invention is to provide a sash frame having bearing surfaces on its sides at the corner joints thereof for reducing sliding friction and Wear in use.

Other objects and features of the invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which:

Fig. 1 is a front elevational vievvv of a miter jointed metal Window sash constructed in accordance with prior methods;

Fig. 2 is a. diagrammatic view illustrating the Waste oil material incident to the two saw-cuts required for each miter joint in the manufacture of the Window sash shown in Fig. 1;

Fig. 3 is an elevational view' of a metal window sash embodying the principles of the present invention;

Fig. 4 is: a diagrammatic view illustrating the manner in which the pieces. for the frame shown 2 in Fig. 3 may be cut, with one saw-cut and without waste of material;

Fig. 5 is a fragmentary perspective view illustrating the flush corner joint embodied in the window sash shown in Fig. 3;

Fig. 6 is a fragmentary sectional View of one corner of the sash taken on the line 6--5 of Fig. 5 and particularly illustrating the novel angle bracket comprising the present invention;

Fig. 7 is a vertical sectional View taken on the line 1--1 of Fig. 6;

Fig. 8 is a horizontal sectional View taken along the line 3-8 of Fig. 6;

Fig. 9 is a perspective view oi one of the angle brackets employed in the new sash construction;

Fig. l0 is a view illustrating the manner of assembly of the sash shown in Fig. 3;

Fig. 1l is a fragmentary sectional View similar to Fig. 6, but illustrating a modification embodying bearing strips at the respective corners of the sash for reducing friction and wear; and

Fig. 12 is a perspective view of the bearing strips shown in Fig. 11.

It has been more or less conventional practice heretofore to construct a metal Window sash frame, such as shown in Fig. l, from side members I! and l2, a top member i3 and a bottom member i4, all bevelled at their ends to provide a miter joint at each corner of the frame. The frame members ll to M are secured together by concealed angle brackets l5 with the aid of screws and rivets (not shown). The frame members ll to Hl are cut from channel-shaped stock I6, Fig. 2; two saw-cuts disposed at an angle of 90 to each other being necessary, as indicated at il and i8, resulting in a substantial waste of the sawyers time and in the Waste of a triangular piece of stock indicated by the numeral IS.

The new sash construction, Fig. 3, includes side frame members 2li and 2i, a top frame member 22, and a bottom frame member 23. The frame members 2B to 23 are likewise formed from channel stock 2li illustrated in Fig. 4, but only a single saw-cut 25 at' right angles to the stock isv necessary to provide the desired squared ends on any two pieces forming a corner joint of the sash frame, as will become apparent hereinafter. None of the material is wasted as an incident to cutting, other than that cut through by the saw blade, and the time and expense of labor in manipulating the saw and in handling the stock to produce a second cut for each corner joint is eliminated.

The frame members 2S to 23 are preferably formed from aluminum alloy strips, either rolled or extruded, in view of the corrosion-resistant and easy-working properties of such material. However, any other metal suitable for the purpose can be used in lieu thereof.

The joints at the respective corners of the new sash are identical and a description of one will suiice for all. Thus, referring to Figs. 6 to 8, inclusive, the side frame member 23 is channelshaped in cross-section and includes parallel flanges or side walls 26 and 21 interconnected along one edge by a transverse base wall or web 28. The top frame member 22 likewise comprises flanges 29 and 33 and an interconnecting base wall or web 3|. at right angles to the side member 20, with the lower edges of the flanges 29 and 3B engaging the upper squared end of the side member 20, and

with the squared end of the top member 22 flush with the outer surface of the wall 28 of said side member. That is to say, the anges 29 and 30 are directly engaged with the ends of the flanges 26 and 21.

The frame members 2! and 22 are secured together in the relationship described by means of a true right angle bracket 33, which is also preferably formed of aluminum alloy, the bracket having a uniform width, indicated by the dimension A, Fig. 9, which is substantially equal t that of the width of the groove in the channelshaped members 2B and 22. Four angle brackets 33 are required for a complete sash, as shown in Fig. 3. These angle brackets are preferably made by cutting the same from a bar of stock having webs disposed at 90 to each other and of the cross-sectional shape best illustrated in Fig. 6. The angle brackets 33 are preferably severed by a rotating saw wetted by a suitable cutting solution, so that the sides of the angle brackets are substantially smooth and free from burrs. Each bracket 33 has a. short leg 34 and a relatively longer leg 35 disposed perpendicularly thereto. The leg 35 is cut away or recessed on the outer face thereof at a region 33 extending inwardly from the outer end of said leg to a shoulder 3i. The recessed or cut-away portion 36 has a depth or dimension B which is equal to the thickness of the transverse Wall 28 of the side member 2B. Thus, a projection 38 is formed on the leg 35 adapted to be disposed directly above the Wall 28 of the frame member 20 and to have its outer face disposed ush with the adjacent squared end of the top member 22. The height of the projection 38 is indicated by the dimension C and in practice is made a few thousandths of an inch less than the depth of the channel in the top member 22. The portion of the leg 35 beyond the shoulder 3? has a dimension D which is substantially equal to the length of the other leg 34, indicated by the dimension E, so that the leg portion 34 engaged with the top member 22 is substantially equal in length to the leg portion 3'5 engaged by the side member 20. f

The leg 34 has a hole 40 drilled therein and this hole may be threaded, if desired, to receive a screw 4| for fastening the outer face of the leg 34 in tight engagement with the inner surface of the Wall 3| of the top member 22. The leg 35 has a hole 42 drilled therethrough, which may also be threaded, if desired, for the reception of a screw 43 for securing the outer face of the leg 35 in tight engagement with the inner surface of the wall 28 of the side member 2li.

A drilled and countersunk hole 44 is formed in the Wall 3| of the top member 22 at a prede- The top member 22 is disposed.

termined distance from the squared end thereof so that it is aligned with the hole 40 in the angle bracket 33. The side member 28 also has a drilled and countersunk hole 45 formed in the wall 28 thereof at a predetermined distance from its end so that it lines up with the hole 42 in said bracket.A rlhe holes in the frame members 2D and 22 are located by placing said members in suitable jigs during the drilling and countersinking operation. Similarly, the holes 40 and 42 may be drilled in the angle brackets 33 by placing said brackets in a jig mounted on a drill press so that the holes in the legs 34 and 35 are correctly drilled to line up with the holes 44 and 45 in the top and side members 22 and 23, respectively. Thus, mass production methods may be employed throughout in the fabrication of the parts constituting the sash frame.

`It will be understood that rivets may be used in lieu of the screws 43 for fastening the angle brackets to the frame members 20 and 2l to speed assembly of the sash. In this connection, and in order to further expedite assembly, a pair of angle brackets 33 may be preassembled with the side members 24 and 2|, as illustrated in Fig. l0. A rectangular sheet of glass 46 having a strip of U-shaped gasket material 41 mounted thereon and extending around its entire periphery is positioned between the frame members 20 and 2|, as shown, with the gasket inserted into the channels of said rframe members as far asv permitted by the beaded portions 48 of said gasket material. The sub-assembly of the glass 46 and frame members 23 and 2| is placed upony a support (not shown) and then the top and bot tom members 22 and 23 are aligned with the frame members 2l! `and 2i to receive the legs 34- of the angle brackets 33 and all of the parts are clamped in position by clamping means (not shown) so that the screws 4| may be threaded into the angle brackets 33 to complete the assembly. The clamping fixture employed is such that it holds the frame members 2G and 2|-in square relation so that the resulting sash is true and the frame members 22 an-d 23 are drawn down tightly against the squared ends of the frame members 2S and 2|. Alternatively, of course, the angle brackets 33 can be first attached to the top and bottom members 22 and 23 to form subassemblies, and these frame members applied to the glass 46, and the side members l2|] and 2| thereafter applied to said glass. As is best shown in Figs. 7 and 8, the thickness of the bracket legs 34 and 35 is equal to about half the depth .-of the grooves in the .frame members 2E and 22`in order to provide ample space for the reception of the gasket 41 and the corner of s the glass 46.

It will be understood that the frame members 22 and 23 can be varied in length to suit the width of any window, and that the side members 2B and 2l can likewise be varied in length to suit a window of any height. Frame 'members of different lengths and widths may be sold `in package form, if desired, and shipped in a knocked down condition and assembled to form sash frames ofdiiferent size, if desired, at theplace of use. Glass and gasket material for the window" sash may be purchased locally, thereby reduclngff the danger of loss by breakage incident to ship-"1` ment of completely assembled sash.

It will be apparent that the foregoing construc-Y tion provides a metal sash frame which is ex'f" tremely'rigid and which presents a neat and .pleasing `appearancedue to the ush corners pro; 'r

vided by the novel angle brackets 33 employed therein.

Aluminum alloy sash are usually mounted in aluminum alloy frames, rails or guideways. In views of the poor bearing properties of the aluminum alloy, there is a tendency for the metal on either the sash or the guideways, or both, to gall or scuri, with the result that the sash may not slide freely with respect to the guideways. This possible objection can be avoided by incorporating anti-friction or bearing elements in the sash structure and Figs. 11 and 12 illustrate a modified form of the invention including such elements.

Fig. 12 is a perspective View of a bearing element 5t made of stainless steel or zinc, bent into the general shape of a right angle. The bearing element 5@ comprises a horizontal leg portion 5i and a vertical leg portion 52. The horizontal leg 5l is provided with a hole 53 that registers with the hole 40 in the bracket 33. The size of the leg 34 of the brackets 33 is reduced slightly to compensate for the thickness of the bearing element 50, so that the legs 5I iit snugly between the bracket legs 34 and the inner surface of the wall 3| of the top frame member 22 and the inner surface of the corresponding Wall of the bottom frame member 23. The legs t2 overlie the projections 38 of the brackets 33 and extend slightly beyond the ends of the frame members 22 and so that they can slidably engage with a guide member 5t indicated in dot-and-dash lines.

Fig. 11 shows the bracket legs secured to the side member 2Q by rivets 5&5, and the bracket legs 3d secured to the top and bottom frame members 22 and 23 by screws 5t. The parts are so dimensioned that the screws 5S pull he edges of the anges of the frame members 22 and 23 tightly against the end of the side member 2e,

thus assuring a rigid and square sash structure. f,

Obviously, if desired, screws can be substituted for the rivets 55.

The stainless steel or zinc bearing elements 58 are adapted to slidably engage with the rail 5ft,

without causing any scuiiing or galling thereof and permit free sliding movement of the sash relative to the rail. While Fig. 11 shows only two corners of the sash, it is to be understood that bearing elements are employed at all four corners of the sash.

The feature of a bearing strip to reduce the friction or a sliding window sash is also appliu cable to sliding screens and a screen embodying bearing strips is disclosed and claimed in my copending application, Serial No. 170,656, iiled of ber flush with the outer side of said one fram'e member; an angle bracket having the legs thereof disposed one in each of said frame members; a bearing element including a portion disposed between one leg of said angle bracket and one of said frame members, and another portion extending to the exterior of the frame to form a bearing surface therefor; and means securing said frame members, bracket and bearing element in assembled relation.

In a sash construction, a generally channelshapedrame member having a squared end; an angle bracket having one leg disposed in the groove of said frame member and the outer face of its other leg substantially ush with the squared end of said frame member; a bearing element including a portion disposed between the outer face of said one leg and said frame member and a portion at least partially overlying said outer face of said other leg; and means securing said bearing element and bracket to said frame member.

3. In a sash construction, a generally channelshaped frame member having a squared end; an angle bracket having one leg disposed in said rchannel and the outer face of its other leg substantially ush with the` squared end of said frame member; a bearing element including a portion disposed between the outer face of said one leg and said frame member and a portion at least partially overlying said outer face of said other leg, said other leg extending transversely beyond said frame member and being recessed to a predetermined depth on the outer face thereof beyond said frame member to provide a shoulder lying in substantially the same plane as the edges of the sides of said frame member; and means securing said bracket and bearing element to said frame member.

e. In a sash frame construction, two frame members each generally channel-shaped in transverse cross-section and having squared ends, said frame members being disposed at right angles to each other with their channels facing inwardly and with one squared end of ons of said frame members engaged by the flanges of the other; an angle bracket substantially equal in width to the width oi the channels in said frame members having one leg 'thereof disposed in the channel of said one frame member and its other leg disposed in the channel of said other frame member, said one leg having a projection thereon with the cuter face of said projection disposed flush with the squared end of said other frame member; a bearing strip disposed between said bracket and one of said frame members and having a portion extending beyond said frame members to provide a bearing surface; and means securing the frame members, bracket and bearing strip in assembled relation.

HENRY J. BIANCO.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 917,119 Peach Apr. 6, 1909 2,120,614 Jorss June 14, 1938 2,585,471 Kammerer Feb. 12, 1952 

